Roofing systems and methods

ABSTRACT

A roofing system includes a plurality of insulation boards adapted for overlying a roof deck to form a layer of insulation, and a plurality of cover boards adapted for overlying the layer of insulation. Each of the plurality of insulation boards has opposing planar surfaces and has a facer on at least one planar surface, and each of the plurality of insulation boards includes polyisocyanurate foam having a first polyisocyanurate foam density. Each of the plurality of cover boards has opposing planar surfaces and has a facer on at least one planar surface, and each of the plurality of cover boards includes polyisocyanurate foam having a second polyisocyanurate foam density greater than the first polyisocyanurate foam density. Each of the plurality of cover boards also includes 1% to 25% by weight one or more fillers selected from the group consisting of organic fillers and inorganic fillers

This patent application is a continuation of pending U.S. patentapplication Ser. No. 15/874,770, filed Jan. 18, 2018 and titled “RoofingSystems and Methods”, which is a continuation of U.S. patent applicationSer. No. 15/193,729, filed Jun. 27, 2016 and titled “Roofing Systems andMethods”, (now U.S. Pat. No. 9,909,317), which is a division of U.S.patent application Ser. No. 14/293,004, filed Jun. 2, 2014 and titled“Roofing Systems and Methods”, (now U.S. Pat. No. 9,404,261), which is acontinuation of U.S. patent application Ser. No. 13/908,505, filed Jun.3, 2013 and titled “Prefabricated Roofing Panel Composite”, (nowabandoned), which is a division of U.S. patent application Ser. No.13/209,710, filed Aug. 15, 2011 and titled “Prefabricated Roofing PanelComposite”, (now U.S. Pat. No. 8,479,467), which is acontinuation-in-part of U.S. patent application Ser. No. 12/703,308,filed Feb. 10, 2010 and titled “Roofing Cover Board, Roofing PanelComposites and Method”, (now U.S. Pat. No. 8,105,685), which is acontinuation of U.S. patent application Ser. No. 11/519,042, filed Sep.11, 2006 and titled “Roofing Cover Board, Roofing Panel Composites, andMethod” (now U.S. Pat. No. 7,811,663), which is a continuation-in-partof U.S. patent application Ser. No. 10/984,122, filed Nov. 9, 2004 andtitled “Roofing Cover Board, Roofing Panel Composite, and Method” (nowabandoned), the entire disclosures of which are hereby incorporated byreference herein for all purposes.

BACKGROUND OF THE INVENTION

The subject invention relates to low-slope roofs that are typicallyfound on commercial and industrial buildings and in particular toprefabricated high-density polymer or predominantly polymer materialcover boards and cover board composites and prefabricated roofing panelcomposites which include high-density polymer or predominantly polymermaterial cover boards and low-density polymer or predominantly polymermaterial foam insulation boards, for use on such low-slope roofs and toa method of making the cover boards, the cover board composites, and theroofing panel composites.

Commercial and industrial buildings typically have roofs with low-sloperoof decks. The roofing systems for these roofs with low-slope roofdecks typically include one or more layers of a low-density roofinginsulation, a layer of roofing cover boards that overlie the low-densityroofing insulation layer(s), and a waterproofing membrane that overliesthe layer of cover boards. The layer(s) of low-density insulation, suchas a low-density polymer-based foam insulation, if not protected, can bepartially crushed or otherwise damaged from worker traffic over theinsulation, the placement of heaving objects on the insulation, theweather, and other causes commonly encountered in roofing construction.The layer of roofing cover boards that overlies the one or more layersof low-density insulation, protects the more fragile low densityinsulation from damage, acts as a fire barrier, provides a suitablesubstrate for the attachment of the overlying waterproofing membrane,and augments the insulating function of the low-density insulation. Theuppermost waterproofing membrane layer overlying the cover board layerprotects the underlying cover board and insulation layers from moistureand other adverse climatic conditions. Normally, these three components(the low-density insulation boards, the roofing cover boards, and thewaterproofing membrane) of the roofing system are separatelymanufactured and separately and successively applied to the low-sloperoof deck.

While these roofing systems function very well, there has remained aneed to provide improved roofing cover boards and prefabricated coverboard composites and to provide prefabricated roofing panel compositesthat include at least an insulation board and the improved roofing coverboard, and that, preferably, include an insulation board andprefabricated the roofing cover board composite having a waterproofingmembrane. With the use of such improved roofing cover boards and coverboard composites and prefabricated roofing panel composites, roofingsystems for low-slope roof decks can be improved and/or the time, labor,and other costs associated with the installation of roofing systems onlow-slope roof decks can be reduced. The subject invention providesimproved roofing cover boards, improved prefabricated roofing coverboard and waterproofing membrane composites, improved prefabricatedroofing panel cover board and insulation board composites, improvedprefabricated roofing panel cover board, insulation board, andwaterproofing membrane composites, and improved prefabricated roofingpanel cover board, insulation board, baseboard, and waterproofingmembrane composites. The subject invention also provides these roofingcover boards, roofing cover board composites, and roofing panelcomposites with reinforcing patches or strips that increase the perfastener wind uplift pull through rating for the cover boards, coverboard composites, and roofing panel composites to thereby further reducethe labor and ultimately the overall installed cost of roofing systemsutilizing these cover boards, cover board composites, and roofing panelcomposites. The subject invention also provides a method for making theimproved roofing cover board and the prefabricated roofing panelcomposites including the improved roofing cover board that is highlyproductive, relatively economical, and efficient.

SUMMARY OF THE INVENTION

According to one aspect, a roofing system comprises a plurality ofinsulation boards adapted for overlying a roof deck to form a layer ofinsulation. Each of the plurality of insulation boards has opposingplanar surfaces and has a facer on at least one planar surface, and saideach of the plurality of insulation boards comprises polyisocyanuratefoam having a first polyisocyanurate foam density. The roofing systemfurther comprises a plurality of cover boards adapted for overlying thelayer of insulation. Each of the plurality of cover boards has opposingplanar surfaces and has a facer on at least one planar surface, and saideach of the plurality of cover boards comprises polyisocyanurate foamhaving a second polyisocyanurate foam density greater than the firstpolyisocyanurate foam density. Each of the plurality of cover boardscomprises 1% to 25% by weight one or more fillers selected from thegroup consisting of organic fillers and inorganic fillers. In someembodiments, at least one of the one or more fillers in each of theplurality of cover boards is selected from the group consisting ofpowdered fillers, liquid fillers, and fiber fillers. In someembodiments, at least one of the one or more fillers in each of theplurality of cover boards is selected from the group consisting of fiberreinforcements, fungi growth-inhibiting agents, and fire-retardants. Insome embodiments, at least one of the one or more fillers in each of theplurality of cover boards is selected from the group consisting oflimestone (CaCO₃), fiberglass, recycled polyisocyanurate dust,extenders, plasticizers, ground up foam insulation, ground up rubber,and wood dust.

In some embodiments, each of the plurality of insulation boardscomprises 1% to 25% by weight one or more fillers selected from thegroup consisting of organic fillers and inorganic fillers. In someembodiments, at least one of the one or more fillers in each of theplurality of insulation boards is selected from the group consisting ofpowdered fillers, liquid fillers, and fiber fillers. In someembodiments, at least one of the one or more fillers in each of theplurality of insulation boards is selected from the group consisting offiber reinforcements, fungi growth-inhibiting agents, andfire-retardants. In some embodiments, at least one of the one or morefillers in each of the plurality of insulation boards is selected fromthe group consisting of limestone (CaCO₃), fiberglass, recycledpolyisocyanurate dust, extenders, plasticizers, ground up foaminsulation, ground up rubber, and wood dust.

In some embodiments, the second polyisocyanurate foam density is between6 lbs/ft³ and 25 lbs/ft³. In some embodiments, the secondpolyisocyanurate foam density is between 4 lbs/ft³ and 25 lbs/ft³. Insome embodiments, the first polyisocyanurate foam density is less than 4lbs/ft³. In some embodiments, the first polyisocyanurate foam density isbetween about 1 lbs/ft³ and about 3 lbs/ft³. The facers may compriseglass fiber. In some embodiments, each of the plurality of cover boardsis bonded to a respective one of the plurality of insulation boards toform a roofing panel composite. In some embodiments, the roofing systemfurther comprises a waterproofing membrane adapted for overlying thelayer of cover boards. In some embodiments, the greater polyisocyanuratefoam density of the plurality of cover boards provides for a compressivestrength to resist deformation.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic perspective view of a prefabricated high-densitypolymer or predominantly polymer material cover board of the subjectinvention.

FIG. 2 is a schematic perspective view of a cover board composite of thesubject invention that includes a prefabricated high-density polymer orpredominantly polymer material cover board and a top facer.

FIG. 3 is a schematic perspective view of a prefabricated roofing panelcomposite of the subject invention that includes a high-density polymeror predominantly polymer material cover board and a low-density polymeror predominantly polymer material foam insulation board.

FIG. 4 is a schematic perspective view of a prefabricated roofing panelcomposite of the subject invention that includes a high-density polymeror predominantly polymer material cover board composite with a top facerand a low-density polymer or predominantly polymer material foaminsulation board.

FIG. 5 is a schematic perspective view of a prefabricated roofing panelcomposite of the subject invention that includes a high-density polymeror predominantly polymer material cover board, a low-density polymer orpredominantly polymer material foam insulation board, and a high-densitypolymer or predominantly polymer material baseboard.

FIG. 6 is a schematic perspective view of a prefabricated roofing panelcomposite of the subject invention that includes a high-density polymeror predominantly polymer material cover board composite with a topfacer, a low-density polymer or predominantly polymer material foaminsulation board, a high-density polymer or predominantly polymermaterial baseboard.

FIG. 7 is a schematic side view of a first production line that can beused with the method of the subject invention to make a prefabricatedroofing panel composite of the subject invention that includes ahigh-density polymer or predominantly polymer material cover board and alow-density polymer or predominantly polymer material foam insulationboard.

FIG. 8 is a schematic side view of a second production line that can beused with the method of the subject invention to make a prefabricatedroofing panel composite of the subject invention that includes ahigh-density polymer or predominantly polymer material cover board and alow-density polymer or predominantly polymer material foam insulationboard.

FIG. 9 is a schematic side view of a production line that can be usedwith the method of the subject invention to make a prefabricated roofingpanel composite of the subject invention that includes a high-densitypolymer or predominantly polymer material cover board, a low-densitypolymer or predominantly polymer material foam insulation board, and ahigh-density polymer or predominantly polymer material baseboard.

FIG. 10 is a schematic side view of a third production line that can beused with the method of the subject invention to make a prefabricatedroofing panel composite of the subject invention that includes ahigh-density polymer or predominantly polymer material cover board and alow-density polymer or predominantly polymer material foam insulationboard.

FIG. 11 is a fragmentary, transverse schematic, perspective view of acover board composite of the subject invention, at a fastener location,wherein the composite includes a reinforcement for increasing thefastener wind-uplift pull through rating of the cover board composite.The Figure also shows a portion of a fastener plate that can be usedwith the composite.

FIG. 12 is a fragmentary, partially exploded, transverse schematic,perspective view of the cover board composite of FIG. 11 at a fastenerlocation.

FIG. 13 is a fragmentary, transverse schematic, perspective view of aprefabricated cover board/insulation board panel composite of thesubject invention, at a fastener location, wherein the panel compositeincludes a reinforcement for increasing the fastener wind-uplift pullthrough rating of the panel composite. The Figure also shows a portionof a fastener plate that can be used with the panel composite.

FIG. 14 is a fragmentary, schematic, perspective view of a prefabricatedcover board/insulation board/baseboard panel composite of the subjectinvention, at a fastener location, wherein the panel composite includesa reinforcement for increasing the fastener wind-uplift pull throughrating of the panel composite. The Figure also shows a portion of afastener plate that can be used with the composite.

FIG. 15 is a schematic bottom view of the prefabricated cover board,cover board/insulation board panel, or cover board/insulationboard/baseboard panel composites of FIGS. 11 to 14, with the bottomfacer removed, to show a reinforcement patch pattern for increasing thefastener wind-uplift pull through rating of the composites.

FIG. 16 is a schematic bottom view of the prefabricated cover board,cover board/insulation board panel, or cover board/insulationboard/baseboard panel composites of FIGS. 11 to 14, with the bottomfacer removed, to show a double-layer reinforcement patch pattern forincreasing the fastener wind-uplift pull through rating of thecomposites.

FIG. 17 is a schematic bottom view of the prefabricated cover board,cover board/insulation board panel, or cover board/insulationboard/baseboard panel composites of FIGS. 11 to 14, with the bottomfacer removed, to show a reinforcement strip pattern for increasing thefastener wind-uplift pull through rating of the composites.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

FIG. 1 is a schematic perspective view of the cover board 10 of thesubject invention, which has a high-density polymer or predominantlypolymer material core layer 12. The high-density polymer orpredominantly polymer material core layer 12 of the cover board 10 has adensity of at least 4 lbs/ft³ and preferably between 6 lbs/ft³ and 25lbs/ft³. The high-density polymer or predominantly polymer material corelayer 12 of the cover board 10 has a thickness of about 0.08 inches orgreater and, preferably, a thickness between about 0.25 inches and about0.75 inches. The density and thickness of the high-density polymer orpredominantly polymer material core layer 12 of the cover board 10 areselected to provide the cover board with the compressive strength toresist deformation and protect low-density insulation layers overlaid bythe cover board from damage, and to provide surface characteristics thatpromote the bonding of a top facer, e.g. a waterproofing membrane, tothe high-density core layer of the cover board.

The high-density polymer or predominantly polymer material core layer 12has a top major surface 14 and a bottom major surface 16 that are eachdefined by the length and the width of the high-density polymer orpredominantly polymer material core layer. The high-density polymer orpredominantly polymer material core layer 12 typically has a width ofabout four feet or greater and a length of about four feet or greater,preferably, about eight feet or greater and could have lengths that arelimited only by the ability to store, transport, and handle thehigh-density polymer or predominantly polymer material cover board 10prior to installation.

The cover board 10 may have top and/or bottom facers that are not shownin FIG. 1. When used, the top and/or bottom facers typically overlie theentire or substantially the entire major surface 14 and/or 16 of thehigh-density polymer or predominantly polymer material core layer 12 towhich the facers are bonded. The top and bottom facers of thehigh-density polymer or predominantly polymer material cover board 10may be any sheet material that provides suitable top and bottom majorsurfaces for the cover board, such as but not limited to paper, foil,woven or nonwoven mats made of fiberglass or other fibers or filaments,scrims, etc.

The high-density polymer or predominantly polymer material core layer 12of the cover board 10 may be made of various high-density polymer orpredominantly polymer materials [e.g. a high-density polyisocyanurate,polyurethane, polystyrene, or phenolic material or a high-densitymaterial made of a blend of these materials; a high-densitypolyisocyanurate, polyurethane, polystyrene, or phenolic foam materialor a high-density foam material made of a blend of these materials; ahigh-density predominantly polyisocyanurate, polyurethane, polystyrene,or phenolic material with up to 40% by weight, but typically betweenabout 1% and about 25% by weight organic and/or inorganic filler(s) or ahigh-density material made of a blend of these materials with up to 40%by weight, but typically between about 1% and about 25% by weightorganic and/or inorganic filler(s); a high-density predominantlypolyisocyanurate, polyurethane, polystyrene, or phenolic foam materialwith up to 40% by weight, but typically between about 1% and about 25%by weight organic and/or inorganic filler(s) or a high-density foammaterial made of a blend of these materials with up to 40% by weight,but typically between about 1% and about 25% by weight organic and/orinorganic filler(s), a high-density material made of other thermosetmatrix polymers; etc.]. However, a preferred material for thehigh-density core layer 12 is a high-density polyisocyanurate orpredominantly polyisocyanurate material or foam material with up to 40%by weight, but typically between about 1% and about 25% by weightorganic and/or inorganic. Examples of various fillers that may be usedin the predominantly polymer materials of the high-density core layer 12include but are not limited to powdered, liquid, and fiber fillers. Thehigh-density polymer and predominantly polymer materials of the corelayer 12 may also include fiber reinforcements, fungi growth-inhibitingagents, and fire-retardants to reduce the cost of and/or modify theproperties of the high-density core layer 12, such as but not limited tothe compressive strength, the toughness, the flexibility, thefriability, and the fire resistance of the core layer. Examples offillers that may be used in the high-density predominantly polymermaterial core layer 12 are fillers such as but not limited to limestone(CaCO₃), fiberglass, recycled polyisocyanurate dust,extenders/plasticizers, ground up foam insulation, ground up rubber,wood dust, etc.

The prefabricated high-density polymer or predominantly polymer materialcover board of the subject invention is relatively lightweight andeasily cut. This makes the cover board easier to install and increasesthe productivity of workers installing the cover boards. Thehigh-density polymer or predominantly polymer material cover board ofthe subject invention does not support mold growth and the cover boardis not negatively impacted by the application of solvents, hot asphalt,or adhesives.

FIG. 2 is a schematic perspective view of a prefabricated cover boardand facer composite 20 of the subject invention. The composite 20includes the cover board 10 and a facer 22, e.g. a waterproofingmembrane. Other than the inclusion of a top facer 22, the prefabricatedcover board and facer composite 20 is the same as the cover board 10 ofFIG. 1.

The top facer 22 of the composite 20 may be any sheet material thatprovides a suitable top major surface for the cover board and facercomposite, such as but not limited to coated or uncoated paper, foil,coated or uncoated woven or nonwoven mats made of fiberglass or otherfibers or filaments, scrims, etc. A preferred sheet material for the topfacer 22 is a nonwoven fiberglass mat that is heavily coated with amineral coating such as but not limited to a calcium carbonate/clay/SBRlatex coating. Where the composite 20 is fully adhered to an underlyingroofing layer (e.g. an insulation layer) rather than being secured bymechanical fasteners, a sheet material may be used for the top facer 22that serves the dual function of providing a facing during themanufacturing process and a waterproofing membrane on the finishedproduct such as but not limited to a bituminous or modified bituminousmembrane, or a single ply membrane (e.g. a EPDM, PVC, or TPO membrane).Where the top facer 22 is a waterproofing membrane, the facer may extendbeyond the high-density polymer or predominantly polymer material corelayer of the cover board 10 on one or more of the four sides of the corelayer (e.g. beyond a side edge and an end edge of the top major surfaceof the core layer) to form membrane overlaps for sealing to themembranes of other composites 20. While not shown, the composite mayalso include a bottom facer that is bonded to the bottom major surfaceof the high-density polymer or predominantly polymer material core layerof the cover board. When used, the bottom facer of the composite 20 maybe any sheet material that provides a suitable bottom major surface forthe cover board and facer composite for bonding to an underlying layerof the roofing system, such as but not limited to coated or uncoatedpaper, coated or uncoated woven or nonwoven mats made of fiberglass orother fibers or filaments, scrims, etc.

FIG. 3 is a schematic perspective view of a first prefabricated roofingpanel composite 30 of the subject invention. The prefabricated roofingpanel composite 30 includes a high-density polymer or predominantlypolymer material cover board 32 and an insulation board 34 that, asshown, are bonded directly together. The prefabricated roofing panelcomposite 30 has a top major surface 36 and a bottom major surface 38that are each defined by the length and the width of the roofing panelcomposite. The prefabricated roofing panel composite 30 typically has awidth of about four feet or greater and a length of about four feet orgreater, preferably, about eight feet or greater and could have lengthsthat are limited only by the ability to store, transport and handle theroofing panel composites prior to installation.

In the prefabricated roofing panel composite 30, the cover board 32 hasa high-density polymer or predominantly polymer material core layer 40.The high-density polymer or predominantly polymer material core layer 40of the cover board 32 in the prefabricated roofing panel composite 30has a density of at least 4 lbs/ft³ and preferably, between 6 lbs/ft³and 25 lbs/ft³. The high-density polymer or predominantly polymermaterial core layer 40 of the cover board 32 in the prefabricatedroofing panel composite has a thickness of about 0.08 inches or greaterand, preferably, a thickness between about 0.25 inches and about 0.75inches. The density and thickness of the high-density polymer orpredominantly polymer material core layer 40 of the cover board 32 areselected to provide the cover board with the compressive strength toresist deformation and protect the low-density insulation board 34 thatis overlaid by the cover board from damage, and to provide surfacecharacteristics that promote the bonding of a top facer, e.g. awaterproofing membrane, to the high-density core layer 40 of the coverboard.

The insulation board 34 in the prefabricated roofing panel composite 30includes a low-density polymer or predominantly polymer material foamcore layer 42. The low-density polymer or predominantly polymer materialfoam core layer 42 of the insulation board 34 has a density less than 6lbs/ft³, preferably less than 4 lbs/ft³, and typically a density of lessthan 2.5 lbs/ft³. The low-density polymer or predominantly polymermaterial foam core layer 42 has a thickness of about 0.50 inches orgreater and, preferably, a thickness between about 0.50 inches and about6 inches. The density and thickness of the low-density polymer orpredominantly polymer material foam core layer 42 of the insulationboard 34 are selected to provide the prefabricated roofing panelcomposite 30 with the desired insulating properties for the roofingsystem application.

The high-density polymer or predominantly polymer material core layer 40of the cover board 32 may be made of various high-density polymer orpredominantly polymer materials [e.g. a high-density polyisocyanurate,polyurethane, polystyrene, or phenolic material or a high-densitymaterial made of a blend of these materials; a high-densitypolyisocyanurate, polyurethane, polystyrene, or phenolic foam materialor a high-density foam material made of a blend of these materials; ahigh-density predominantly polyisocyanurate, polyurethane, polystyrene,or phenolic material with up to 40% by weight, but typically betweenabout 1% and about 25% by weight organic and/or inorganic filler(s) or ahigh-density material made of a blend of these materials with up to 40%by weight, but typically between about 1% and about 25% by weightorganic and/or inorganic fillers); a high-density predominantlypolyisocyanurate, polyurethane, polystyrene, or phenolic foam materialwith up to 40% by weight, but typically between about 1% and about 25%by weight organic and/or inorganic filler(s) or a high-density foammaterial made of a blend of these materials with up to 40% by weight,but typically between about 1% and about 25% by weight organic and/orinorganic filler(s), a high-density material made of other thermosetmatrix polymers; etc.]. However, a preferred material for thehigh-density core layer 40 is a high-density polyisocyanurate orpredominantly polyisocyanurate material or foam material with up to 40%by weight, but typically between about 1% and about 25% by weightorganic and/or filler(s) such as but not limited to those listed abovein connection with the cover board 10.

The low-density polymer or predominantly polymer material foam corelayer 42 of the insulation board 34 may be made of various low-densitypolymer or predominantly polymer foam materials [e.g. a low-densitypolyisocyanurate, polyurethane, polystyrene, or phenolic foam materialor a low-density foam material made of a blend of these materials; alow-density predominantly polyisocyanurate, polyurethane, polystyrene,or phenolic foam material with up to 40% by weight, but typicallybetween about 1% and about 25% by weight organic and/or inorganicfiller(s) or a low-density foam material made of a blend of thesematerials with up to 40% by weight, but typically between about 1% andabout 25% by weight organic and/or filler(s), a low-density foammaterial made of other thermoset matrix polymers; etc.]. However, apreferred material for the low-density core layer 42 is a low-densitypolyisocyanurate or predominantly polyisocyanurate foam material up to40% by weight, but typically between about 1% and about 25% by weightorganic and/or inorganic filler(s).

When the high-density core layer 40 is made of a predominantly polymermaterial, the high-density predominantly polymer material of the corelayer 40 may contain various powdered, liquid, and fiber fillers, fiberreinforcements, fire-retardants, fungi growth-inhibiting agents, etc. toreduce the cost and/or modify the properties of the high-density corelayer 40 (such as but not limited to the compressive strength, theflexibility, the friability, the fire resistance of the core layer).When the low-density core layer 42 is made of a predominantly polymermaterial foam, the low-density predominantly polymer material foam corelayer 42 may contain various powdered, liquid, and fiber fillers, fiberreinforcements, fire-retardants, fungi growth-inhibiting agents, etc. toreduce the cost and/or modify the properties of the low-densitypredominantly polymer material foam core layer. Examples of fillers thatmay be used in the high-density core layer 40 of the cover board 32 andthe low-density core layer 42 of the insulation board 34 are fillerssuch as but not limited to limestone (CaCO₃), fiberglass, recycledpolyisocyanurate dust, extenders/plasticizers, ground up foaminsulation, ground up rubber, wood dust, etc.

While, as shown in FIG. 3, the prefabricated roofing panel composite 30has no facers, the prefabricated roofing panel composite 30 could have acommon facer intermediate and bonded to both the bottom major surface ofthe cover board core layer 40 and the top major surface of theinsulation board core layer 42, a top facer bonded to the top majorsurface of the cover board core layer 40, and/or a bottom facer bondedto the bottom major surface of the insulation board core layer 42. Whenused, the common facer of the prefabricated roofing panel composite 30may be any sheet material with good bonding surfaces that facilitates agood bond between the cover board 32 and insulation board 34, such asbut not limited to woven or nonwoven mats made of glass fibers, otherfibers or filaments, scrims, etc. When used, the top facer of theprefabricated roofing panel composite 30 overlies the entire orsubstantially the entire top major surface of the high-density corelayer 40 of the cover board 32. The top facer of the prefabricatedroofing panel composite 30 may be any sheet material that provides asuitable top major surface for the prefabricated roofing panel composite30, such as but not limited to coated or uncoated paper, foil, coated oruncoated woven or nonwoven mats made of fiberglass or other fibers orfilaments, scrims, etc. When used, the bottom facer of the prefabricatedroofing panel composite 30 overlies the entire or substantially theentire bottom surface of the low-density foam core layer 42 of theinsulation board 34. The bottom facer of the prefabricated roofing panelcomposite 30 may be any sheet material that provides a suitable bottommajor surface for the roofing panel composite 30, such as but notlimited to coated or uncoated paper, foil, coated or uncoated woven ornonwoven mats made of fiberglass or other fibers or filaments, scrims,etc.

FIG. 4 is a schematic perspective view of a prefabricated roofing panelcomposite 50 of the subject invention. The prefabricated roofing panelcomposite 50 includes the high-density polymer or predominantly polymermaterial cover board 32 and the low-density polymer or predominantlypolymer material foam insulation board 34 that, as shown in FIG. 4, arebonded directly together, and a top facer 52. Other than the inclusionof the top facer 52, the prefabricated roofing panel composite 50 is thesame as the prefabricated roofing panel composite 30 of FIG. 3.

The top facer 52 of the prefabricated roofing panel composite 50 isbonded to and overlies the entire or substantially the entire topsurface of the high-density polymer or predominantly polymer materialcore layer of the cover board 32. The top facer 52 of the prefabricatedroofing panel composite 50 may be any sheet material that provides asuitable top major surface for the cover board of the prefabricatedroofing panel composite 50, such as but not limited to coated oruncoated paper, foil, coated or uncoated woven or nonwoven mats made offiberglass or other fibers or filaments, scrims, etc. A preferred sheetmaterial for the top facer 52 is a nonwoven fiberglass mat that isheavily coated with a mineral coating such as but not limited to acalcium carbonate/clay/SBR latex coating. Where the prefabricatedroofing panel composite 50 is fully adhered to an underlying roofinglayer (e.g. an insulation layer) rather than being secured by mechanicalfasteners, a sheet material may be used for the top facer 52 that servesthe dual function of providing a facing during the manufacturing processand a waterproofing membrane on the finished product such as but notlimited to a bituminous or modified bituminous membrane, or a single plymembrane (e.g. a EPDM, PVC, or TPO membrane). Where the top facer 52 isa waterproofing membrane, the facer may extend beyond the high-densitycore layer of the cover board 32 on one or more of the four sides of thecore layer, e.g. beyond a side edge and an end edge of the top majorsurface of the core layer to provide overlaps for sealing with themembranes of adjacent panels.

While, as shown in FIG. 4, the prefabricated roofing panel composite 50only has a top facer 52, the prefabricated roofing panel composite 50could have a common facer intermediate and bonded to both the bottommajor surface of the cover board 32 core layer 40 and the top majorsurface of the insulation board 34 core layer 42, and/or a bottom facerbonded to the bottom major surface of the insulation board 34 core layer42. When used, the common facer of the prefabricated roofing panelcomposite 50 may be any sheet material with good bonding surfaces thatfacilitates a good bond between the cover board 32 and insulation board34, such as but not limited to woven or nonwoven mats made of glassfibers, other fibers or filaments, scrims, etc. When used, the bottomfacer of the prefabricated roofing panel composite 50 overlies theentire or substantially the entire bottom surface of the low-densityfoam core layer of the insulation board 34. The bottom facer of theprefabricated roofing panel composite 50 may be any sheet material thatprovides a suitable bottom major surface for the roofing panel composite50, such as but not limited to coated or uncoated paper, foil, coated oruncoated woven or nonwoven mats made of fiberglass or other fibers orfilaments, scrims, etc.

FIG. 5 is a schematic perspective view of a prefabricated roofing panelcomposite 60 of the subject invention that includes: a high-densitypolymer or predominantly polymer material cover board 62, a low-densitypolymer or predominantly polymer material foam insulation board 64, anda high-density polymer or predominantly polymer material baseboard 66.The high-density polymer or predominantly polymer material cover board62 and baseboard 66 may have the same density or different densities. Asshown in FIG. 5, the cover board 62, the insulation board 64, and thebaseboard 66 are bonded directly together. The prefabricated roofingpanel composite 60 has a top major surface 68 and a bottom major surface70 that are each defined by the length and the width of theprefabricated roofing panel composite. The prefabricated roofing panelcomposite 60 typically has a width of about four feet or greater and alength of about four feet or greater, preferably, about eight feet orgreater and could have lengths that are limited only by the ability tostore, transport and handle the roofing panel composites prior toinstallation.

In the prefabricated roofing panel composite 60, the cover board 62 hasa high-density polymer or predominantly polymer material core layer 72and the baseboard 66 has a high-density polymer or predominantly polymermaterial core layer 74. The high-density polymer or predominantlypolymer material core layers 72 and 74 each have a density of at least 4lbs/ft³ and preferably, between 6 lbs/ft³ and 25 lbs/ft³. Thehigh-density polymer or predominantly polymer material core layer 72 ofthe cover board 62 and the high-density polymer or predominantly polymermaterial core layer 74 of the baseboard 66 each have a thickness ofabout 0.08 inches or greater and, preferably, a thickness between about0.25 inches and about 0.75 inches. The density and thickness of thehigh-density polymer or predominantly polymer material core layer 72 ofthe cover board 62 are selected to provide the cover board with thecompressive strength to resist deformation and protect the low-densityinsulation board 64 that is overlaid by the cover board from damage, andto provide surface characteristics that promote the bonding of a topfacer, e.g. a waterproofing membrane, to the core layer 72 of the coverboard.

The insulation board 64 in the prefabricated roofing panel composite 60includes a low-density polymer or predominantly polymer foam core layer76. The low-density polymer or predominantly polymer material foam corelayer 76 of the insulation board 64 has a density less than 6 lbs/ft³,preferably less than 4 lbs/ft³, and typically a density of less thanabout 2.5 lbs/ft³. The low-density polymer or predominantly polymermaterial foam core layer 76 has a thickness of about 0.50 inches orgreater and, preferably, a thickness between about 0.50 inches and about6 inches. The density and thickness of the low-density polymer orpredominantly polymer material foam core layer 76 of the insulationboard 64 are selected to provide the prefabricated roofing panelcomposite 60 with the desired insulating properties for the roofingsystem application.

The high-density polymer or predominantly polymer material core layers72 and 74 of the cover board 62 and the baseboard 66 may be made ofvarious high-density polymer or predominantly polymer materials [e.g. ahigh-density polyisocyanurate, polyurethane, polystyrene, or phenolicmaterial or a high-density material made of a blend of these materials;a high-density polyisocyanurate, polyurethane, polystyrene, or phenolicfoam material or a high-density foam material made of a blend of thesematerials; a high-density predominantly polyisocyanurate, polyurethane,polystyrene, or phenolic material with up to 40% by weight, buttypically between about 1% and about 25% by weight organic and/orinorganic filler(s) or a high-density material made of a blend of thesematerials with up to 40% by weight, but typically between about 1% andabout 25% by weight organic and/or inorganic filler(s); a high-densitypredominantly polyisocyanurate, polyurethane, polystyrene, or phenolicfoam material with up to 40% by weight, but typically between about 1%and about 25% by weight organic and/or inorganic filler(s) or ahigh-density foam material made of a blend of these materials with up to40% by weight, but typically between about 1% and about 25% by weightorganic and/or inorganic filler(s), a high-density material made ofother thermoset matrix polymers; etc.]. However, a preferred materialfor the high-density core layers 72 and 74 is a high-densitypolyisocyanurate or predominantly polyisocyanurate material or foammaterial up to 40% by weight, but typically between about 1% and about25% by weight organic and/or inorganic filler(s).

The low-density polymer or predominantly polymer material foam corelayer 76 of the insulation board 64 may be made of various low-densitypolymer or predominantly polymer foam materials [e.g. a low-densitypolyisocyanurate, polyurethane, polystyrene, or phenolic foam materialor a low-density foam material made of a blend of these materials; alow-density predominantly polyisocyanurate, polyurethane, polystyrene,or phenolic foam material with up to 40% by weight, but typicallybetween about 1% and about 25% by weight organic and/or inorganicfiller(s) or a low-density foam material made of a blend of thesematerials with up to 40% by weight, but typically between about 1% andabout 25% by weight organic and/or inorganic filler(s), a low-densitymaterial made of other thermoset matrix polymers; etc.]. However, apreferred material for the low-density core layer 76 is a low-densitypolyisocyanurate or predominantly polyisocyanurate foam material up to40% by weight, but typically between about 1% and about 25% by weightorganic and/or inorganic filler(s).

When the high-density core layers 72 and 74 are made of a predominantlypolymer material, the high-density predominantly polymer material of thecore layers 72 and 74 may contain various powdered, liquid, and fiberfillers, fiber reinforcements, fire-retardants, fungi growth-inhibitingagents, etc. to reduce the cost and/or modify the properties of thehigh-density core layers 72 and 74 (such as but not limited to thecompressive strength, the flexibility, the friability, the fireresistance of the core layer). When the low-density core layer 76 ismade of a predominantly polymer material foam, the low-densitypredominantly polymer material foam core layer 76 may contain variouspowdered, liquid and fiber fillers, fiber reinforcements,fire-retardants, fungi growth-inhibiting agents, etc. to reduce the costand/or modify the properties of the low-density foam core layer.Examples of fillers that may be used in the high-density core layers 72of the cover board 62 and the baseboard 66 and the low-density corelayer 76 of the insulation board 64 are fillers such as but not limitedto limestone (CaCO₃), fiberglass, recycled polyisocyanurate dust,extenders/plasticizers, ground up foam insulation, ground up rubber,wood dust, etc.

While, as shown in FIG. 5, the prefabricated roofing panel composite 60has no facers, the prefabricated roofing panel composite 60 could have acommon facer intermediate and bonded to both the bottom major surface ofthe cover board core layer 72 and the top major surface of theinsulation board core layer 76, a common facer intermediate and bondedto both the bottom major surface of the insulation board core layer 76and the top major surface of the baseboard core layer 74, a top facerbonded to the top major surface of the cover board core layer 72, and/ora bottom facer bonded to the bottom major surface of the baseboard corelayer 74. When used, the common facers of the prefabricated roofingpanel composite 60 may be any sheet material with good bonding surfacesthat facilitates a good bond between the cover board 62, the insulationboard 64, and the baseboard 66, such as but not limited to woven ornonwoven mats made of glass fibers, other fibers or filaments, scrims,etc. When used, the top facer of the prefabricated roofing panelcomposite 60 overlies the entire or substantially the entire top majorsurface of the high-density core layer 72 of the cover board 62. The topfacer of the prefabricated roofing panel composite 60 may be any sheetmaterial that provides a suitable top major surface for theprefabricated roofing panel composite 60, such as but not limited tocoated or uncoated paper, foil, coated or uncoated woven or nonwovenmats made of fiberglass or other fibers or filaments, scrims, etc. Whenused, the bottom facer of the prefabricated roofing panel composite 60overlies the entire or substantially the entire bottom surface of thehigh-density core layer 74 of the baseboard 66. The bottom facer of theprefabricated roofing panel composite 60 may be any sheet material thatprovides a suitable bottom major surface for the roofing panel composite60, such as but not limited to coated or uncoated paper, foil, coated oruncoated woven or nonwoven mats made of fiberglass or other fibers orfilaments, scrims, etc.

FIG. 6 is a schematic perspective view of a prefabricated roofing panelcomposite 80 of the subject invention. The prefabricated roofing panelcomposite 80 includes the high-density polymer or predominantly polymermaterial cover board 62, the low-density polymer or predominantlypolymer material foam insulation board 64, and the high-density polymeror predominantly polymer material baseboard 66, that, as shown in FIG.6, are bonded directly together, and a top facer 82. Other than theinclusion of a top facer 82, the prefabricated roofing panel composite80 of FIG. 6 is the same as the prefabricated roofing panel composite 60of FIG. 5.

The top facer 82 of the prefabricated roofing panel composite 80 isbonded to and overlies the entire or substantially the entire topsurface of the high-density polymer or predominantly polymer materialcore layer of the cover board 62. The top facer 82 of the prefabricatedroofing panel composite 80 may be any sheet material that provides asuitable top major surface for the cover board and facer composite, suchas but not limited to coated or uncoated paper, foil, coated or uncoatedwoven or nonwoven mats made of fiberglass or other fibers or filaments,scrims, etc. A preferred sheet material for the top facer 82 is anonwoven fiberglass mat that is heavily coated with a mineral coatingsuch as but not limited to a calcium carbonate/clay/SBR latex coating.Where the prefabricated roofing panel composite 80 is fully adhered toan underlying roofing layer (e.g. an insulation layer) rather than beingsecured by mechanical fasteners, a sheet material may be used for thetop facer 82 that serves the dual function of providing a facing duringthe manufacturing process and a waterproofing membrane on the finishedproduct such as but not limited to a bituminous or modified bituminousmembrane, or a single ply membrane (e.g. a EPDM, PVC, or TPO membrane).Where the top facer 82 is a waterproofing membrane, the facer may extendbeyond the high-density polymer or predominantly polymer material corelayer of the cover board 62 on one or more of the four sides of the corelayer, e.g. beyond a side edge and an end edge of the top major surfaceof the core layer to provide membrane overlaps for sealing with themembranes of adjacent panels.

While, as shown in FIG. 6, the prefabricated roofing panel composite 80only has a top facer 82, the prefabricated roofing panel composite 80could have a common facer intermediate and bonded to both the bottommajor surface of the cover board core layer and the top major surface ofthe insulation board core layer, a common facer intermediate and bondedto both the bottom major surface of the insulation board core layer andthe top major surface of the baseboard core layer, and/or a bottom facerbonded to the bottom major surface of the baseboard core layer. Whenused, the common facers of the prefabricated roofing panel composite 80may be any sheet material with good bonding surfaces that facilitates agood bond between the cover board and insulation board and theinsulation board and the baseboard, such as but not limited to woven ornonwoven mats made of glass fibers, other fibers or filaments, scrims,etc. When used, the bottom facer of the prefabricated roofing panelcomposite 80 overlies the entire or substantially the entire bottomsurface of the high-density core layer of the baseboard 66. The bottomfacer of the prefabricated roofing panel composite 80 may be any sheetmaterial that provides a suitable bottom major surface for theprefabricated roofing panel composite 80, such as but not limited tocoated or uncoated paper, foil, coated or uncoated woven or nonwovenmats made of fiberglass or other fibers or filaments, scrims, etc.

FIG. 7 is a schematic side view of a first production line 100 that canbe used with the method of the subject invention to continuously makeprefabricated roofing panel composites of the subject invention in line,such as the prefabricated roofing panel composites 30 of FIG. 3 and 50of FIG. 4. The prefabricated roofing panel composites 30 and 50 eachinclude a high-density polymer or predominantly polymer material coverboard 32 and a low-density polymer or predominantly polymer materialfoam insulation board 34. The production line 100 includes: a firstforming station 102 for forming the low-density polymer or predominantlypolymer material foam insulation board 34 of the prefabricated roofingpanel composites 30 and 50; a second forming station 104 for forming thehigh-density polymer or predominantly polymer material cover board 32 ofthe prefabricated roofing panel composites 30 and 50; and a cuttingstation 106 for cutting the prefabricated roofing panel composites 30and 50 to length.

The first forming station 102 for forming the low-density foaminsulation board 34 includes a conventional dispenser 108 for dispensinga low-density polymer or predominantly polymer material foam precursor110 (e.g. a low-density polyisocyanurate or predominantlypolyisocyanurate foam precursor) onto a facer, when used, overlying aconveyor 112 of two spaced-apart opposed forming conveyers 112 and 114or directly onto the conveyor 112. As the foam precursor 110 passesbetween the forming conveyors 112 and 114, foams and at least partiallysets, the forming conveyors 112 and 114 cooperate to set the thicknessof the low-density polymer or predominantly polymer material foam corelayer 42 of the low-density polymer or predominantly polymer foaminsulation board 34 formed from the precursor 110. The first formingstation 102 also includes supplies (e.g. rolls) of facer materials 116and 118 that can be fed over and/or beneath the low-density polymer orpredominantly polymer material foam precursor 110 to form a common facerof the prefabricated roofing panel composites 30 and 50 and a bottomfacer of the prefabricated roofing panel composites 30 and 50.

The second forming station 104 of the production line 100 for formingthe high-density polymer or predominantly polymer material cover board32 of the prefabricated roofing panel composites 30 and 50 includes aconventional dispenser 120 for dispensing a high-density polymer orpredominantly polymer material or foam precursor 122 (e.g. ahigh-density polyisocyanurate or predominantly polyisocyanurate foamprecursor) onto the low-density polymer or predominantly polymermaterial foam core layer 42 or, when used, a common facer overlying thelow-density polymer or predominantly polymer material foam core layer42. With the high-density polymer or predominantly polymer materialprecursor 122 overlying the low-density foam core layer 42 or, whenused, the common facer, the high-density polymer or predominantlypolymer material precursor 122 and the low-density foam core layer 42pass between two spaced-apart opposed forming conveyers 112 and 124where the high-density polymer or predominantly polymer material corelayer 38 is formed and bonded directly to the low-density foam corelayer 42 or to the common facer overlying the low-density foam corelayer 42. The spaced-apart opposed forming conveyors 112 and 124cooperate to set the thickness of both the high-density polymer orpredominantly polymer material core layer 40 and the prefabricatedroofing panel composite 30 or 50. The second forming station 104 alsoincludes supplies (e.g. rolls) of a facer material 126 that is fed overthe high-density polymer or predominantly polymer material precursor 122to form the top facer 52 of both the high-density cover board 32 and theprefabricated roofing panel composite 50.

With the high-density core layer 40 and the low-density foam core layer42 of the prefabricated roofing panel composite 30 or 50 bonded togetherin the second forming station 104 to form a continuous length of theprefabricated roofing panel composite 30 or 50, the prefabricatedroofing panel composite 30 or 50 is then cut to length to complete theformation of the prefabricated roofing panel composite 30 or 50. In thecutting station 106 a cutter, such as but not limited to a reciprocatingcutter 128, cuts the prefabricated roofing panel composite 30 or 50coming from the second forming station 104 to length.

While the production line 100, as shown, is capable of applying threefacer materials 116, 118, and 126 to the insulation board 34 and thecover board 32 to form the prefabricated roofing panel composites 30 and50. The application of any one, any two, or all of the facing materials116, 118 and 126 to the insulation board and cover board can be omittedto form the prefabricated roofing panel composite 30 and all but the topfacing material can be omitted to form the prefabricated roofing panelcomposite 50 with the desired number of facers. The facers 116, 118 and126 normally prevent the polymer or predominantly polymer layers fromsticking to the conveyors. However, with a shift in the chemistry of theprecursors 110 and 122 to affect the tackiness of the layers produced sothat they do not stick to the surfaces of the conveyors or by applyingrelease films or coatings to the surfaces of the conveyers that will notallow the layers produced to stick to the surfaces of the conveyors,when desired, any one or all of the facing materials are not needed forand could be eliminated from the manufacturing process.

FIG. 8 is a schematic side view of a second production line 200 that canbe used with the method of the subject invention to continuously makeprefabricated roofing panel composites of the subject invention, such asthe prefabricated roofing panel composites 30 of FIG. 3 and 50 of FIG.4. The prefabricated roofing panel composites 30 and 50 each include ahigh-density polymer or predominantly polymer material cover board and alow-density polymer or predominantly polymer material foam insulationboard. The production line 200 includes: an in-feed conveyor 202 forcontinuously feeding a series of low-density polymer or predominantlypolymer material foam insulation boards 34 of the prefabricated roofingpanel composite into a forming station 204; the forming station 204 forforming the high-density polymer or predominantly polymer material coverboard 32 of the prefabricated roofing panel composites 30 and 50; and acutting station 206 for cutting the prefabricated roofing panelcomposites 30 and 50 to length.

The low-density polymer or predominantly polymer material foaminsulation boards 34 may include a top facer that, when used, forms acommon facer of the prefabricated roofing panel composites 30 and 50 andmay include a bottom facer that, when used, forms a bottom facer of theprefabricated roofing panel composites. Preferably, the low-densitypolymer or predominantly polymer material foam insulation boards 34 arefed into the forming station 204 lengthwise with the ends of successiveinsulation boards 34 in the continuous series of insulation boardsabutting each other.

The forming station 204 of the production line 200 for forming thehigh-density polymer or predominantly polymer material cover board 32 ofthe prefabricated roofing panel composite 30 includes a conventionaldispenser 208 for dispensing the high-density polymer or predominantlypolymer material precursor 210 (e.g. a high-density polyisocyanurate orpredominantly polyisocyanurate precursor) directly onto the low-densityfoam core layers 42 of the insulation boards 34 or, when used the commonfacers overlying the low-density foam core layers of the low-densityfoam insulation boards. With the high-density polymer or predominantlypolymer material precursor 210 directly overlying the low-density foamcore layers 42 of the insulation boards or the common facers 36 carriedby the low-density foam insulation boards 34, the high-density polymeror predominantly polymer material precursor 210 and the low-density foaminsulation boards 34 pass between two spaced-apart opposed formingconveyers 212 and 214 where the high-density polymer or predominantlypolymer material core layers 38 of the cover boards 32 are formed andbonded directly to the low-density foam core layers 42 of the insulationboards 34 or to the common facers overlying the low-density foaminsulation board 34. The spaced-apart opposed forming conveyors 212 and214 cooperate to set the thickness of both the high-density polymer orpredominantly polymer material core layer 40 and the prefabricatedroofing panel composite 30 or 50. The forming station 204 also includessupplies (e.g. rolls) of a facer material 216 that is fed over thehigh-density polymer or predominantly polymer material precursor 210 toform the top facer 52 of both the high-density polymer or predominantlypolymer material cover board 32 and the prefabricated roofing panelcomposite 50.

With the high-density core layer 40 and the low-density foam core layer42 of the prefabricated roofing panel composite 30 or 50 bonded togetherin the forming station 204 to form a continuous length of theprefabricated roofing panel composite 30 or 50, the prefabricatedroofing panel composite 30 or 50 is then cut to length to complete theformation of the prefabricated roofing panel composite 30 or 50. In thecutting station 206 a cutter, such as but not limited to a reciprocatingcutter 218, cuts the prefabricated roofing panel composite 30 comingfrom the forming station 204 to length.

The production line 200, as shown, is capable of making theprefabricated roofing panel composite 30 by feeding preformedlow-density polymer or predominantly polymer material foam insulationboards 34 into the forming station 204 and omitting the application ofthe facer material 216 to the cover board 32 and is capable of makingthe prefabricated roofing panel composite 50 by feeding preformedlow-density polymer or predominantly polymer material foam insulationboards 34 into the forming station 204 and applying of the facermaterial 216 to the cover board 32. The facer 216 normally prevents thehigh-density polymer or predominantly polymer material layer fromsticking to the conveyor 212. However, with a shift in the chemistry ofthe precursor 210 to affect the tackiness of the layer produced so thatthe layer does not stick to the surface of the conveyor 212 or byapplying a release film or coating to the surface of the conveyer 212that will not allow the layer produced to stick to the surface of theconveyor, when desired, the facing materials 216 is not needed for andcould be eliminated from the manufacturing process.

FIG. 9 is a schematic side view of a production line 300 that can beused with the method of the subject invention to continuously make aprefabricated roofing panel composite of the subject invention, such asthe prefabricated roofing panel composites 60 of FIG. 5 and 80 of FIG.6. These prefabricated roofing panel composites each include: ahigh-density polymer or predominantly polymer material cover board 62, alow-density polymer or predominantly polymer material foam insulationboard 64, and a high-density polymer or predominantly polymer materialbaseboard 66. The production line 300 includes: a first forming station302 for forming the high-density polymer or predominantly polymermaterial baseboard 66 of the prefabricated roofing panel composites 60and 80; a second forming station 304 for forming the low-density polymeror predominantly polymer material foam insulation board 64 of theprefabricated roofing panel composites 60 and 80; a third formingstation 306 for forming the high-density polymer or predominantlypolymer material cover board 62 of the prefabricated roofing panelcomposites 60 and 80; and a cutting station 308 for cutting theprefabricated roofing panel composites 60 and 80 to length.

The first forming station 302 for forming the high-density polymer orpredominantly polymer material baseboard 56 includes a conventionaldispenser 310 for dispensing a high-density polymer or predominantlypolymer material precursor 312 (e.g. a high-density polyisocyanurate orpredominantly polyisocyanurate precursor) onto a facer, when used,overlying a conveyor 314 of two spaced-apart opposed forming conveyers314 and 316 or directly onto the conveyor 314. As the precursor 310passes between the forming conveyors 314 and 316, forms and at leastpartially sets, the forming conveyors 314 and 316 cooperate to set thethickness of the high-density polymer or predominantly polymer materialcore layer 74 of the high-density baseboard 66 formed from the precursor310. The first forming station 302 also includes supplies (e.g. rolls)of facer materials 318 and 320 that may be fed over and/or beneath thehigh-density polymer or predominantly polymer material precursor 310 toform, when used, a common facer of the prefabricated roofing panelcomposites 60 and 80 and a bottom facer of the prefabricated roofingpanel composites 60 and 80.

The second forming station 304 of the production line 300 for formingthe low-density polymer or predominantly polymer material foaminsulation board 64 of the prefabricated roofing panel composites 60 and80 includes a conventional dispenser 322 for dispensing a low-densitypolymer or predominantly polymer material foam precursor 324 (e.g. alow-density polyisocyanurate or predominantly polyisocyanurate foamprecursor) directly onto the high-density core layer 74 or, when used,onto a common facer overlying the high-density core layer 74 of thebaseboard 66. With the low-density polymer or predominantly polymermaterial foam precursor 324 directly overlying high-density core layer74 or the common facer overlying the high-density core layer 74 of thebaseboard 66, the low-density polymer or predominantly polymer materialfoam precursor 324 and the high-density core layer 74 pass between twospaced-apart opposed forming conveyers 314 and 326 where the low-densitypolymer or predominantly polymer material foam core layer 76 of theinsulation board 64 is formed and bonded to the high-density core layer74 or the common facer overlying the high-density core layer 74 of thebaseboard 66. The spaced-apart opposed forming conveyors 314 and 326cooperate to set the thickness of the low-density polymer orpredominantly polymer material foam core layer 76 of the insulationboard 64. The second forming station 304 also includes supplies (e.g.rolls) of a facer material 328 that can be fed over the low-densitypolymer or predominantly polymer material foam precursor 324 to form acommon facer of the prefabricated roofing panel composites 60 and 80.

The third forming station 306 of the production line 300 for forming thehigh-density polymer or predominantly polymer material cover board 62 ofthe prefabricated roofing panel composites 60 and 80 includes aconventional dispenser 330 for dispensing a high-density polymer orpredominantly polymer material precursor 332 (e.g. a high-densitypolyisocyanurate or predominantly polyisocyanurate precursor) directlyonto the low-density foam core layer 76 or the common facer overlyingthe low-density foam core layer 76 of the insulation board 64. With thehigh-density polymer or predominantly polymer material precursor 332overlying the low-density foam core layer 76 or the common faceroverlying the low-density foam core layer 76, the high-density polymeror predominantly polymer material precursor 332, the low-density foaminsulation board 64, and the high-density baseboard 66 pass between twospaced-apart opposed forming conveyers 314 and 334 where thehigh-density polymer or predominantly polymer material core layer 72 ofthe cover board 62 is formed and bonded to the low-density foam corelayer 76 or the common facer overlying the low-density foam core layer76 of the insulation board 64. The spaced-apart opposed formingconveyors 314 and 334 cooperate to set the thickness of both thehigh-density polymer or predominantly polymer material core layer 72 andthe prefabricated roofing panel composite 60 or 80. The third formingstation 306 also includes supplies (e.g. rolls) of a facer material 336that is fed over the high-density polymer or predominantly polymermaterial precursor 332 to form the top facer 82 of both the high-densitycover board 62 and the prefabricated roofing panel composite 80.

With the high-density polymer or predominantly polymer material coverboard 62, the low-density polymer or predominantly polymer material foaminsulation board 64, and the high-density polymer or predominantlypolymer material baseboard 66 of the prefabricated roofing panelcomposites 60 or 80 bonded together in the third forming station 306 toform a continuous length of the prefabricated roofing panel composite 60or 80, the prefabricated roofing panel composite 60 or 80 is then cut tolength to complete the formation of the prefabricated roofing panelcomposite 60 or 80. In the cutting station 308 a cutter, such as but notlimited to a reciprocating cutter 338, cuts the continuous prefabricatedroofing panel composite 60 or 80 coming from the third forming station306 to length.

While the production line 300, as shown, is capable of applying fourfacer materials 318, 320, 328, and 336 to the baseboard 66, theinsulation board 64 and the cover board 62 to form the prefabricatedroofing panel composites 60 and 80. The application of any one, any two,any three or all of the facing materials 318, 320, 328, and 336 to thebaseboard, the insulation board and the cover board can be omitted toform the prefabricated roofing panel composite 60 and all but the topfacing material can be omitted to form the prefabricated roofing panelcomposite 80 with the desired number of facers. The facers 318, 320,328, and 336 normally prevent the composite layers from sticking to theconveyors. However, with a shift in the chemistry of the precursors312,324, and 332 to affect the tackiness of the layers produced so thatthey do not stick to the surfaces of the conveyors or by applyingrelease films or coatings to the surfaces of the conveyers that will notallow the layers produced to stick to the surfaces of the conveyors,when desired, any one or all of the facing materials are not needed forand could be eliminated from the manufacturing process.

FIG. 10 is a schematic side view of another production line 400 that canbe used with the method of the subject invention to continuously makeprefabricated roofing panel composites of the subject invention in line,such as the prefabricated roofing panel composites 30 of FIG. 3 and 50of FIG. 4. The prefabricated roofing panel composites 30 and 50 eachinclude a high-density polymer or predominantly polymer material coverboard 32 and a low-density polymer or predominantly polymer materialfoam insulation board 34. The production line 400 includes: a formingstation 402 for forming the low-density polymer or predominantly polymermaterial foam insulation board 34 and the high-density polymer orpredominantly polymer material cover board 32 of the prefabricatedroofing panel composites 30 and 50; and a cutting station 404 forcutting the prefabricated roofing panel composites 30 and 50 to length.

The forming station 402 for forming the low-density foam insulationboard 34 and the high-density cover board includes a conventionaldispenser 406 for dispensing a low-density polymer or predominantlypolymer material foam precursor 408 (e.g. a low-density polyisocyanurateor predominantly polyisocyanurate foam precursor) onto a facer, whenused, overlying a conveyor 410 of two spaced-apart opposed formingconveyers 410 and 412 or directly onto the conveyor 410. The formingstation 402 also includes a conventional dispenser 414 for dispensing ahigh-density polymer or predominantly polymer material precursor 416(e.g. a high-density polyisocyanurate or predominantly polyisocyanuratematerial precursor) onto the low-density polymer or predominantlypolymer material foam precursor of the core layer 42 or, when used, acommon facer overlying the low-density polymer or predominantly polymermaterial foam precursor of the core layer 42. As the layers of precursor408 and 416 pass between the forming conveyors 410 and 412, theprecursors form and at least partially set, the forming conveyors 410and 412 cooperate to set the thickness of the low-density polymer orpredominantly polymer material foam core layer 42 of insulation board 34formed from the precursor 408, the thickness of the high-density polymeror predominantly polymer material core layer 40 of cover board 32 formedfrom the precursor 416, and the thickness of the prefabricated roofingpanel composite 30 or 50. The forming station 402 also includes supplies(e.g. rolls) of facer materials 418, 420, and 422 that can be fed overand/or beneath the low-density polymer or predominantly polymer materialfoam precursor 408 to form a common facer of the prefabricated roofingpanel composites 30 and 50 and a bottom facer of the prefabricatedroofing panel composites 30 and 50 and that can be fed over thehigh-density polymer or predominantly polymer material precursor 416 toform a top facer of the prefabricated roofing panel composites 30 and50.

With the high-density core layer 40 and the low-density foam core layer42 of the prefabricated roofing panel composite 30 or 50 bonded togetherto form a continuous length of the prefabricated roofing panel composite30 or 50, the prefabricated roofing panel composite 30 or 50 is then cutto length to complete the formation of the prefabricated roofing panelcomposite 30 or 50. In the cutting station 404 a cutter, such as but notlimited to a reciprocating cutter 424, cuts the prefabricated roofingpanel composite 30 or 50 coming from the forming station 402 to length.

While the production line 400, as shown, is capable of applying threefacer materials 418, 420 and 422 to the insulation board 34 and thecover board 32 to form the prefabricated roofing panel composites 30 and50. The application of any one, any two, or all of the facing materials418, 420, and 422 to the insulation board and cover board can be omittedto form the prefabricated roofing panel composite 30 and all but the topfacing material can be omitted to form the prefabricated roofing panelcomposite 50 with the desired number of facers. The facers 418, 420, and422 normally prevent the layers of the composite from sticking to theconveyors. However, with a shift in the chemistry of the precursors 408and 416 to affect the tackiness of the layers produced so that they donot stick to the surfaces of the conveyors or by applying release filmsor coatings to the surfaces of the conveyers that will not allow thelayers produced to stick to the surfaces of the conveyors, when desired,any one or all of the facing materials are not needed for and could beeliminated from the manufacturing process.

Preferably, the low-density polymer or predominantly polymer materialfoam precursors 110, 324, and 408 are low-density polyisocyanurate orpredominantly polymer foam precursors. Preferably, the high-densitypolymer or predominantly polymer material precursors 122, 210, 312, 332,and 416 are high-density polyisocyanurate or predominantlypolyisocyanurate material precursors. The high-density polymer orpredominantly polymer material precursors 122, 210, 312, 332, and 416can be formulated to produce high-density materials or foams bysignificantly reducing or eliminating the blowing agent(s) from theprecursors 122, 210, 312, 332, and 416. Pentane (HFC), micro-spheres,CO₂ and water (as well as other materials) will act as blowing agentsfor the precursors. The relatively high-density layers produced usingthese types of precursors have improved strength characteristics overthe low-density foams normally produced for insulation products. As theamount of blowing agent is reduced in the precursors 122, 210, 312, 332,and 416, the density and the compressive strength of the high-densitylayers produced increase. These types of high-density core layers aremuch more resistant to deformation than the typical low-density foamcore layers.

FIGS. 11 and 12 are fragmentary, transverse schematic, perspective viewsof a prefabricated cover board composite 520 of the subject invention.The composite 520 includes the cover board 10 of FIG. 1, a top facer 522(e.g. a waterproofing membrane), a bottom facer 524, and a plurality ofwind-uplift reinforcement patches 526 (such as but not limited to thewind-uplift reinforcement patches shown in FIGS. 15 and 16) or strips528 (such as but not limited to the wind-uplift reinforcement stripsshown in FIG. 17). Conventional fastener plates, such as but not limitedto the disc shaped metallic fastener plate 530, are typically used ateach fastener penetration of the prefabricated cover board composite 520to spread the forces exerted on the top major surface of the compositeby the nails or other mechanical fasteners securing the composite to aroof deck over a greater surface area and thereby reduce the pressuresexerted by the fasteners (not shown) on the top major surface of thecomposite. Other than the inclusion of a top facer 522, a bottom facer524, and a plurality of wind-uplift reinforcements, such as thewind-uplift reinforcement patches 526 or strips 528 the prefabricatedcover board composite 520 is the same as the cover board 10 of FIG. 1.

The top facer 522 that is bonded to the top major surface of thehigh-density polymer or predominantly polymer material core layer of thecover board composite 520 may be any sheet material that provides asuitable top major surface for the cover board composite, such as butnot limited to coated or uncoated paper, foil, coated or uncoated wovenor nonwoven mats made of fiberglass or other fibers or filaments,scrims, etc. A preferred sheet material for the top facer 522 is anonwoven fiberglass mat that is heavily coated with a mineral coatingsuch as but not limited to a calcium carbonate/clay/SBR latex coating.Where the cover board composite 520 is fully adhered to an underlyingroofing layer (e.g. an insulation layer) rather than being secured bymechanical fasteners, a sheet material may be used for the top facer 522that serves the dual function of providing a facing during themanufacturing process and a waterproofing membrane on the finishedproduct such as but not limited to a bituminous or modified bituminousmembrane, or a single ply membrane (e.g. a EPDM, PVC, or TPO membrane).Where the top facer 522 is a waterproofing membrane, the facer mayextend beyond the high-density polymer or predominantly polymer materialcore layer of the cover board 10 on one or more of the four sides of thecore layer (e.g. beyond a side edge and an end edge of the top majorsurface of the core layer) to form membrane overlaps for sealing to themembranes of other composites 520. The bottom facer 524 is bonded to andtypically coextensive with the bottom major surface of the high-densitypolymer or predominantly polymer material core layer of the cover boardcomposite 520. The bottom facer 524 of the composite 520 may be anysheet material that provides a suitable bottom major surface for thecover board composite 520, such as but not limited to coated or uncoatedpaper, coated or uncoated woven or nonwoven mats made of fiberglass orother fibers or filaments, scrims, etc. However, a preferred bottomfacer 524, is a coated or uncoated woven or nonwoven fiberglass mat suchas but not limited to the preferred top facer 522.

The wind-uplift reinforcements, e.g. the wind-uplift reinforcementpatches 526 (such as but not limited to the wind-uplift reinforcementpatches shown in FIGS. 15 and 16) or the wind-uplift reinforcementstrips 528 (such as but not limited to the wind-uplift reinforcementstrips shown in FIG. 17), may be made of various reinforcement sheet ormat materials, such as but not limited to sheets or mats of glass,polyester, polypropylene, metal, wool, and other synthetic and naturalfibers and combinations of such fibers. However, a preferredreinforcement material for the wind-uplift reinforcements, e.g. thewind-uplift reinforcement patches and strips is a scrim such asfiberglass scrim with a minimum tensile strength of 30 lbs per linearinch and preferably, a minimum tensile strength of at least 100 lbs perlinear inch, e.g. a fiberglass scrim that is 10 grams/ft² with 8×8strands per inch wherein the mean diameter of the strands is 0.019inches.

When a cover board composite is subjected to wind-uplift forces fromhigh winds during service, the wind-uplift forces exerted on a coverboard composite, if not controlled, will tend to place the top portionof the composite in compression and the bottom portion of the compositein tension at the fastener locations to thereby place the compositeunder stress at these locations. Repeated cycles of stress exerted on acover board composite at the fastener locations during service canresult in a failure of the composite at one or more of the fastenerlocations. The wind-uplift reinforcements of the subject invention, e.g.the wind-uplift reinforcement patches 526 or reinforcement strips 528,greatly increase the pressures that the cover board composite canwithstand before failure at a fastener location. While the cover boardcomposite still flexes, the wind-uplift reinforcements of the subjectinvention extend or increase the load the bottom facer can withstandbefore the bottom facer 524 fails at a fastener location. Thewind-uplift reinforcements, e.g. the wind-uplift reinforcement patches526 (such as but not limited to the wind-uplift reinforcement patchesshown in FIGS. 15 and 16) or the wind-uplift reinforcement strips 528(such as but not limited to the wind-uplift reinforcement strips shownin FIG. 17) are interposed between the bottom facer 524 and the bottommajor surface of the core layer to coincide with a selected fastenerpattern or selected fastener patterns for securing the cover boardcomposite 520 to a roof deck and increase a per-fastener wind-upliftpull through rating for the cover board composite.

FIG. 13 is a fragmentary, transverse schematic, perspective view of aprefabricated cover board/insulation board panel composite 540 of thesubject invention. The panel composite 540 includes the coverboard/insulation board panel composite 30 of FIG. 3, which includes acover board 32 with a high-density polymer or predominantly polymermaterial core layer and an insulation board 34 with a low-densitypolymer or predominantly polymer material core layer; a top facer 542(e.g. a waterproofing membrane); a bottom facer 544; and a plurality ofwind-uplift reinforcement patches 546 (such as but not limited to thewind-uplift reinforcement patches shown in FIGS. 15 and 16) or strips548 (such as but not limited to the wind-uplift reinforcement stripsshown in FIG. 17). Fastener plates, such as but not limited to thefastener plate 550, are typically used at each fastener penetration ofthe prefabricated cover board/insulation board panel composite 540 tospread the forces exerted on the top major surface of the panelcomposite by the fasteners securing the composite to a roof deck over agreater surface area and thereby reduce the pressures exerted by thefasteners (not shown) on the top major surface of the panel composite.Other than the inclusion of a top facer 542, a bottom facer 544, and aplurality of wind-uplift reinforcements, such as the wind-upliftreinforcement patches 546 or strips 548 the prefabricated coverboard/insulation board panel composite 540 is the same as the coverboard/insulation board panel composite 30 of FIG. 3.

The top facer 542 that is bonded to the top major surface of thehigh-density polymer or predominantly polymer material core layer of thecover board 32 may be any sheet material that provides a suitable topmajor surface for the cover board/insulation board panel composite 540,such as but not limited to coated or uncoated paper, foil, coated oruncoated woven or nonwoven mats made of fiberglass or other fibers orfilaments, scrims, etc. A preferred sheet material for the top facer 542is a nonwoven fiberglass mat that is heavily coated with a mineralcoating such as but not limited to a calcium carbonate/clay/SBR latexcoating. The bottom facer 544 is bonded to and typically coextensivewith the bottom major surface of the low-density polymer orpredominantly polymer material core layer of the insulation board 34.The bottom facer 544 of the composite 540 may be any sheet material thatprovides a suitable bottom major surface for the cover board/insulationboard composite 540, such as but not limited to coated or uncoatedpaper, coated or uncoated woven or nonwoven mats made of fiberglass orother fibers or filaments, scrims, etc. However, a preferred bottomfacer 544, is a coated or uncoated woven or nonwoven fiberglass mat suchas but not limited to the preferred the top facer 542.

The wind-uplift reinforcements, e.g. the wind-uplift reinforcementpatches 546 (such as but not limited to the wind-uplift reinforcementpatches shown in FIGS. 15 and 16) or the wind-uplift reinforcementstrips 548 (such as but not limited to the wind-uplift reinforcementstrips shown in FIG. 17), may be made of various reinforcement sheet ormat materials, such as but not limited to sheets or mats of glass,polyester, polypropylene, metal, wool, and other synthetic and naturalfibers and combinations of such fibers. However, a preferredreinforcement material for the wind-uplift reinforcements, e.g. thewind-uplift reinforcement patches and strips is a scrim such asfiberglass scrim with a minimum tensile strength of 30 lbs per linearinch and preferably, a minimum tensile strength of at least 100 lbs perlinear inch, e.g. a fiberglass scrim that is 10 grams/ft² with 8×8strands per inch wherein the mean diameter of the strands is 0.019inches. The wind-uplift reinforcements, e.g. the wind-upliftreinforcement patches 546 (such as but not limited to the wind-upliftreinforcement patches shown in FIGS. 15 and 16) or the wind-upliftreinforcement strips 548 (such as but not limited to the wind-upliftreinforcement strips shown in FIG. 17) are interposed between the bottomfacer 544 and the bottom major surface of the insulation board corelayer to coincide with a selected fastener pattern or selected fastenerpatterns for securing the cover board, insulation board panel composite540 to a roof deck and increase a per-fastener wind-uplift pull throughrating for the cover board/insulation board panel composite. Thewind-uplift reinforcements of the cover board/insulation board panelcomposite 540 perform the same or substantially the same function as thewind-uplift reinforcements of the cover board composite 520.

FIG. 14 is a fragmentary, transverse schematic, perspective view of aprefabricated cover board/insulation board/baseboard panel composite 560of the subject invention. The panel composite 560 includes the roofingpanel composite 60 of FIG. 5, which includes a cover board 62 with ahigh-density polymer or predominantly polymer material core layer, aninsulation board 64 with a low-density polymer or predominantly polymermaterial foam core layer; a baseboard 66 with a high-density polymer orpredominantly polymer material core layer; a top facer 562 (e.g. awaterproofing membrane), a bottom facer 564, and a plurality ofwind-uplift reinforcement patches 566 (such as but not limited to thewind-uplift reinforcement patches shown in FIGS. 15 and 16) or strips568 (such as but not limited to the wind-uplift reinforcement stripsshown in FIG. 17). Fastener plates, such as but not limited to thefastener plate 570, are typically used at each fastener penetration ofthe prefabricated cover board/insulation board/baseboard panel composite560 to spread the forces exerted on the top major surface of thecomposite by the fasteners securing the composite to a roof deck over agreater surface area and thereby reduce the pressures exerted by thefasteners (not shown) on the top major surface of the panel composite.Other than the inclusion of a top facer 562, a bottom facer 564, and aplurality of wind-uplift reinforcements, such as the wind-upliftreinforcement patches 566 or strips 568 the prefabricated coverboard/insulation board/baseboard panel composite 560 is the same as thecover board/insulation board/baseboard panel composite 60 of FIG. 5.

The top facer 562 that is bonded to the top major surface of thehigh-density polymer or predominantly polymer material core layer of thecover board 62 may be any sheet material that provides a suitable topmajor surface for the cover board/insulation board/baseboard panelcomposite, such as but not limited to coated or uncoated paper, foil,coated or uncoated woven or nonwoven mats made of fiberglass or otherfibers or filaments, scrims, etc. A preferred sheet material for the topfacer 522 is a nonwoven fiberglass mat that is heavily coated with amineral coating such as but not limited to a calcium carbonate/clay/SBRlatex coating. The bottom facer 564 is bonded to and typicallycoextensive with the bottom major surface of the high-density polymer orpredominantly polymer material core layer of the baseboard 66. Thebottom facer 564 of the composite 560 may be any sheet material thatprovides a suitable bottom major surface for the cover board/insulationboard/baseboard composite 560, such as but not limited to coated oruncoated paper, coated or uncoated woven or nonwoven mats made offiberglass or other fibers or filaments, scrims, etc. However, apreferred bottom facer 564, is a coated or uncoated woven or nonwovenfiberglass mat such as but not limited to the preferred top facer 562.

The wind-uplift reinforcements, e.g. the wind-uplift reinforcementpatches 566 (such as but not limited to the wind-uplift reinforcementpatches shown in FIGS. 15 and 16) or the wind-uplift reinforcementstrips 568 (such as but not limited to the wind-uplift reinforcementstrips shown in FIG. 17), may be made of various reinforcement sheet ormat materials, such as but not limited to sheets or mats of glass,polyester, polypropylene, metal, wool, and other synthetic and naturalfibers and combinations of such fibers. However, a preferredreinforcement material for the wind-uplift reinforcements, e.g. thewind-uplift reinforcement patches and strips is a scrim such asfiberglass scrim with a minimum tensile strength of 30 lbs per linearinch and preferably, a minimum tensile strength of at least 100 lbs perlinear inch, e.g. a fiberglass scrim that is 10 grams/ft² with 8×8strands per inch wherein the mean diameter of the strands is 0.019inches. The wind-uplift reinforcements, e.g. the wind-upliftreinforcement patches 566 (such as but not limited to the wind-upliftreinforcement patches shown in FIGS. 15 and 16) or the wind-upliftreinforcement strips 568 (such as but not limited to the wind-upliftreinforcement strips shown in FIG. 17) are interposed between the bottomfacer 564 and the bottom major surface of the baseboard core layer tocoincide with a selected fastener pattern or selected fastener patternsfor securing the cover board/insulation board/baseboard panel composite560 to a roof deck and increase a per-fastener wind-uplift pull throughrating for the cover board/insulation board/baseboard panel composite.The wind-uplift reinforcements of the cover board/insulationboard/baseboard panel composite 560 perform the same or substantiallythe same function as the wind-uplift reinforcements of the cover boardcomposite 520.

FIGS. 15 and 16 show an eight-fastener wind-uplift reinforcement patchplacement pattern, utilizing a single patch and a double patcharrangement, for securing the cover board composite 520, the coverboard/insulation board panel composite 540, and the coverboard/insulation board/baseboard panel composite 560 to a roofing deck.The eight-fastener wind-uplift reinforcement patch placement patternshown is exemplary and it is to be understood that the wind-upliftreinforcement patch placement patterns for the cover board composite520, the cover board/insulation board panel composite 540, and the coverboard/insulation board/baseboard panel composite 560 can be selected toaccommodate any desired fastener placement pattern including any one ormore of the fastener placement patterns commonly utilized in the roofingindustry. In the embodiment shown in FIG. 15, single wind-upliftreinforcement patches 526, 546, and 566 are utilized. In the embodimentof FIG. 16, double wind-uplift patches 528, 548, and 568 are utilizedwith the overlying wind-uplift reinforcement patches having a 45° offsetrelative to the wind-uplift reinforcement patches overlaid. Preferably,the wind-uplift reinforcement patches 528, 548, and 568 are at leastthree inches by three inches and centered over each of the fastenerplacement locations. Examples of preferred wind-uplift reinforcementpatches are: generally square patches that have dimensions between aboutthree inches by about three inches and about six inches by about sixinches; generally round patches that have diameters between about threeinches and about six inches; and generally rectangular, oval and othershaped patches having a minor dimension between about three inches andabout six inches and a major dimension between about three inches andabout six inches. Preferably, the top surface of a cover board composite520, a cover board/insulation board panel composite 540, or a coverboard/insulation board/baseboard panel composite 560 utilizing thesingle or double wind-uplift reinforcement patches will be visiblymarked to indicate the locations of the wind-uplift reinforcementpatches on the underside of the composite so that a roofing installerwill know exactly where to pass fasteners for securing the composite toa roof deck through the composite and the wind-uplift reinforcementpatches located on the underside of the composite in the fastenerplacement pattern being utilized to secure the composite to a roof deck.For example, visible X and/or 0 markings could be placed on the topsurface of a composite that are centered over the centers of each of thesingle or double wind-uplift reinforcement patches on the underside ofthe composite.

FIG. 17 shows a wind-uplift reinforcement strip placement pattern, whichcan be used for an eight-fastener placement or other fastener placementpattern, for securing the cover board composite 520, the coverboard/insulation board panel composite 540, and the coverboard/insulation board/baseboard panel composite 560 to a roofing deck.The wind-uplift reinforcement strip placement pattern shown for thewind-uplift reinforcement strips 528, 548 and 568 is exemplary and it isto be understood that the reinforcement strip placement patterns for thecover board composite 520, the cover board/insulation board panelcomposite 540, and the cover board/insulation board/baseboard panelcomposite 560 can be selected to accommodate any desired fastenerplacement pattern including any one or more of the fastener placementpatterns commonly utilized in the roofing industry. Preferably, thewind-uplift reinforcement strips 528, 548 and 568 are between aboutthree and about six inches wide, run the length and/or width of thecomposite, and have their longitudinal centerlines centered overfastener placement locations. Preferably, the top surface of a coverboard composite 520, a cover board/insulation board panel composite 540,or a cover board/insulation board/baseboard panel composite 560utilizing the wind-uplift reinforcement strips will be visibly marked toindicate the locations of the wind-uplift reinforcement strips on theunderside of the composite so that a roofing installer will know exactlywhere to pass fasteners for securing the composite to a roof deckthrough the composite and the wind-uplift reinforcement strips locatedon the underside of the composite in the fastener placement patternbeing utilized to secure the composite to a roof deck. For example,visible solid or dashed line markings or visible solid or dashed linemarkings with X and 0 markings in various fastener placement patternscould be placed on the top surface of a composite with the line markingscentered over and extending along the longitudinal centerlines of thewind-uplift reinforcement strips on the underside of the composite.

Tests were conducted to determine fastener pull through strength for a0.25 inch thick polyisocyanurate cover board: a) with only a coatednonwoven glass fiber bottom facer bonded to and substantiallycoextensive with the bottom major surface of the cover board; b) with acoated nonwoven glass fiber bottom facer bonded to and substantiallycoextensive with the bottom major surface of the cover board and a scrimreinforcement interposed between the bottom facer and the bottom majorsurface of the cover board and also substantially coextensive with thebottom major surface of the cover board; c) with a coated nonwoven glassfiber bottom facer bonded to and substantially coextensive with thebottom major surface of the cover board and six inch wide scrimreinforcement strips interposed between the bottom facer and the bottommajor surface of the cover board, running the length of the cover board,and having longitudinal centerlines centered over the fastenerpenetration locations; d) with a coated nonwoven glass fiber bottomfacer bonded to and substantially coextensive with the bottom majorsurface of the cover board and three inch wide scrim reinforcementstrips interposed between the bottom facer and the bottom major surfaceof the cover board, running the length of the cover board, and havinglongitudinal centerlines centered over the fastener penetrationlocations; e) with a coated nonwoven glass fiber bottom facer bonded toand substantially coextensive with the bottom major surface of the coverboard and six inch square scrim reinforcement patches interposed betweenthe bottom facer and the bottom major surface of the cover board andcentered over the fastener penetration locations; and f) with a coatednonwoven glass fiber bottom facer bonded to and substantiallycoextensive with the bottom major surface of the cover board and twolayers of six inch square scrim reinforcement patches interposed betweenthe bottom facer and the bottom major surface of the cover board andcentered over the fastener penetration locations. The scrim materialused in the tests was a fiberglass scrim having a tensile strength of105 lbs per linear inch. The scrim material was 10 grams/ft² with 8×8strands per inch wherein the mean diameter of the strands was 0.019inches. The measured per fastener wind-uplift pull through strengths forthese composites was:

a) coated nonwoven glass fiber facer alone—160 lbf (pounds of force);

b) coated nonwoven glass fiber facer and scrim reinforcement that issubstantially coextensive with the bottom major surface of the coverboard—300 lbf;

c) coated nonwoven glass fiber facer and six-inch wide scrimreinforcement strips—275 lbf;

d) coated nonwoven glass fiber facer and three-inch wide scrimreinforcement strips—250 lbf;

e) coated nonwoven glass fiber facer and six inch square scrimreinforcement patches—240 lbf; and

f) coated nonwoven glass fiber facer and two layers of six-inch squarescrim reinforcement patches—350 lbf.

The coverage rate of the scrim reinforcement (area of the bottom majorsurface of a cover board or other roofing panel composite covered byscrim reinforcement) for the scrim reinforcement embodiments set forthimmediately above will vary with the fastener location pattern utilized.However, for the scrim reinforcement embodiments set forth immediatelyabove, an eight fastener location pattern on a four by eight foot coverboard or other roofing panel composite (i.e. a cover board or otherroofing panel composite with a 32 ft² bottom major surface) results inthe following coverage rates:

a) coated nonwoven glass fiber facer alone—0 ft² coverage;

b) coated nonwoven glass fiber facer and scrim reinforcement that issubstantially coextensive with the bottom major surface of the coverboard—32 ft² coverage;

c) coated nonwoven glass fiber facer and six inch wide scrimreinforcement strips—8 ft² coverage;

d) coated nonwoven glass fiber facer and three inch wide scrimreinforcement strips—4 ft² coverage;

e) coated nonwoven glass fiber facer and six inch square scrimreinforcement patches—2 ft² coverage; and

f) coated nonwoven glass fiber facer and two layers of six inch squarescrim reinforcement patches—2 ft² coverage with 4 ft² of scrim utilized.

With embodiment “f” (coated nonwoven glass fiber facer and two layers ofsix inch square scrim reinforcement patches—2 ft² coverage with 4 ft² ofscrim utilized) a 90 pounds/ft² wind-uplift rating may be achieved for acover board using only eight fasteners to secure the cover board whereasfor embodiment “a” (coated nonwoven glass fiber facer alone) sixteenfasteners must be utilized to achieve a 90 pound/ft² wind-uplift ratingfor the cover board. Fasteners and their installation commonly representapproximately 40% of cover board installation costs. The scrimreinforcements of the subject invention enable a reduction in the numberof fasteners required to achieve a specific wind-uplift rating for aninstalled cover board. Thus, for a roofing system with a specificwind-uplift rating, the scrim reinforcements of the subject inventioncan significantly reduce the labor and ultimately, the overall installedcost of the roofing system. Of course, an installer can retain thenormal number of fasteners utilized per cover board and significantlyincrease the wind-uplift rating for the installed cover board. Inaddition, while the use of a scrim reinforcement that is substantiallycoextensive with the bottom major surface of a cover board or otherroofing panel composite can significantly increase the per fastenerwind-uplift pull through rating, the scrim reinforcement of the subjectinvention can substantially reduce the square footage of scrimreinforcement required to significantly increase the per fastenerwind-uplift pull through rating (e.g. 32 ft² for full scrimreinforcement coverage vs. 8 ft², 4 ft², or 2 ft² coverage forreinforcements of the subject invention for an eight fastener locationpattern on a four by eight foot cover board or other roofing panelcomposite).

In describing the invention, certain embodiments have been used toillustrate the invention and the practices thereof. However, theinvention is not limited to these specific embodiments as otherembodiments and modifications within the spirit of the invention willreadily occur to those skilled in the art on reading this specification.For example, the prefabricated roofing panel composites could be in anupside down orientation to that shown and described in connection withFIGS. 7 to 9. Thus, the invention is not intended to be limited to thespecific embodiments disclosed, but is to be limited only by the claimsappended hereto.

What is claimed is:
 1. A roofing system, comprising: a plurality ofinsulation boards adapted for overlying a roof deck to form a layer ofinsulation, each of the plurality of insulation boards having opposingplanar surfaces and having a facer on at least one planar surface, andsaid each of the plurality of insulation boards comprisingpolyisocyanurate foam having a first polyisocyanurate foam density; anda plurality of cover boards adapted for overlying the layer ofinsulation, each of the plurality of cover boards having opposing planarsurfaces and having a facer on at least one planar surface, and saideach of the plurality of cover boards comprising polyisocyanurate foamhaving a second polyisocyanurate foam density greater than the firstpolyisocyanurate foam density, wherein each of the plurality of coverboards comprises 1% to 25% by weight one or more fillers selected fromthe group consisting of organic fillers and inorganic fillers.
 2. Theroofing system of claim 1, wherein at least one of the one or morefillers in each of the plurality of cover boards is selected from thegroup consisting of powdered fillers, liquid fillers, and fiber fillers.3. The roofing system of claim 1, wherein at least one of the one ormore fillers in each of the plurality of cover boards is selected fromthe group consisting of fiber reinforcements, fungi growth-inhibitingagents, and fire-retardants.
 4. The roofing system of claim 1, whereinat least one of the one or more fillers in each of the plurality ofcover boards is selected from the group consisting of limestone (CaCO₃),fiberglass, recycled polyisocyanurate dust, extenders, plasticizers,ground up foam insulation, ground up rubber, and wood dust.
 5. Theroofing system of claim 1, wherein each of the plurality of insulationboards comprises 1% to 25% by weight one or more fillers selected fromthe group consisting of organic fillers and inorganic fillers.
 6. Theroofing system of claim 5, wherein at least one of the one or morefillers in each of the plurality of insulation boards is selected fromthe group consisting of powdered fillers, liquid fillers, and fiberfillers.
 7. The roofing system of claim 5, wherein at least one of theone or more fillers in each of the plurality of insulation boards isselected from the group consisting of fiber reinforcements, fungigrowth-inhibiting agents, and fire-retardants.
 8. The roofing system ofclaim 5, wherein at least one of the one or more fillers in each of theplurality of insulation boards is selected from the group consisting oflimestone (CaCO₃), fiberglass, recycled polyisocyanurate dust,extenders, plasticizers, ground up foam insulation, ground up rubber,and wood dust.
 9. The roofing system of claim 1, wherein the secondpolyisocyanurate foam density is between 6 lbs/ft³ and 25 lbs/ft³. 10.The roofing system of claim 1, wherein the second polyisocyanurate foamdensity is between 4 lbs/ft³ and 25 lbs/ft³.
 11. The roofing system ofclaim 1, wherein the first polyisocyanurate foam density is less than 4lbs/ft³.
 12. The roofing system of claim 1, wherein the firstpolyisocyanurate foam density is between about 1 lbs/ft³ and about 3lbs/ft³.
 13. The roofing system of claim 1, wherein the facers compriseglass fiber.
 14. The roofing system of claim 1, wherein each of theplurality of cover boards is bonded to a respective one of the pluralityof insulation boards to form a roofing panel composite.
 15. The roofingsystem of claim 1, further comprising a waterproofing membrane adaptedfor overlying the layer of cover boards.
 16. The roofing system of claim1, wherein the greater polyisocyanurate foam density of the plurality ofcover boards provides for a compressive strength to resist deformation.